Float under the wire



Dec. 18, 1956 F. W. E. HOESELBARTH FLOAT UNDER THE WIRE Filed July 5,1955 INVEN ATTORNEYS United States Patent FLOAT UNDER THE WIRE Frank W.E. Hoeselbarth, Carlisle, Pa., assignor to C. -H.

Masland & Sons, Carlisle, Pa., a corporation of Pennsylvania ApplicationJuly 5, 1955, Serial No. 519,747

6 Claims. (Cl. 139-403) The present invention relates to pile carpetsproduced on Jacquard looms, of the type of Wilton or Brussels.

A purpose of the invention is to achieve high uncut pile loops orsprouts appearing at the face of a carpet in cut pile areas.

A further purpose is to create low floats beneath wires in a relativelylow cut pile area which will rise above the cut pile by reason of thecombination of resilience due to length and bulkiness, .and springinessdue to the length of the float which was initially held down under thewires and then released.

A further purpose is to employ a lofty pile yarn so as to obtainadequate -bulk when the yarn has to spring up in the pile, desirablyusing a twist in the ply (suitably two or three ply) of from 1 to 2.5turns per inch.

Further purposes appear in the specification and in the claims.

In the drawings I have chosen to illustrate one only of the numerousembodiments in which my invention appears, selecting the forms shownfrom the standpoints of convenience in illustration, satisfactoryoperation and clear demonstration of the principles involved.

Figure 1 is a warpwise standard weave diagram showing the structure ofthe invention prior to withdrawing the wires.

Figure 2 is similar to Figure 1 showing the same fabric after the wireshave been withdrawn.

In the prior art it has been ditficult to introduce high uncut pileloops in cut pile areas of carpets without employing additional wiresfor the uncut loops. It will be evident that the use of the additionalwires increases the time taken in weaving and adds to the expense, whileat the same time interfering with tightness of weaving.

By the present invention it is possible to obtain uncut loops in cutpile areas due to a resilient or spring efiect which pushes up long orthick low floats during weaving. A residual stress is released when thewires are withdrawn and the fabric comes off the spike roll and is nolonger restrained by the wires, so that suitable low floats rise abovethe cut pile.

The residual stress in the low floats may be introduced by providingvery long floats which extend over three or more upper or face wefts incombination with a very low cut pile, or this result can be accomplishedby using very heavy face warp ends and permissibly shorter low floatswhich extend over at least two upper wefts.

Especially when using a heavy face warp yarn, it is decidedly preferableto use a lofty yarn having a twist in the ply of l to 2.5 turns perinch. The number or" plies will most desirably be three or more,although two ply yarn may be employed for this purpose.

In accordance with Figure 1, I there illustrate binder warps 2G and 21,stufier warps 22 and pile warp ends 23 and 24 which are manipulated by ajacquard. Upper wefts 25 and lower wefts 26 are provided as well-knownin carpet weaving.

Considering the weave of Figure l, in the first step pile warp ends 23are raised to the upper position, binder 2,774,390 Patented Dec. 18.,19.56

warp ends 26 are raised to the intermediate position, forming an uppershed, and all other warp ends are placed in the lower position, forminga lower shed. .A cutting wire of a height not in excess of 0.150 inch isinserted in the upper shed, the wire 27 preferably being in the rangefrom 0.100 to 0.150 inch. In the second step, binder warp 21 is loweredand all other warps are raised half way, forming a lower shed into whicha shot of weft 26 is inserted.

On the third step, pile warp 24 is fully raised, pile warp 30 is raisedhalf way, binder warp 21 is raised half way, and all other warps arelowered. Cutting wire 27 similar to the wire mentioned above is insertedin the upper shed and a shot of weft 25 is taken in the lower shed. Inthe fourth step, binder warp 20 is lowered, all other warps are raisedhalf way, and a shot of weft 26 is taken in the lower shed.

In the fifth step, pile warp 23 is fully raised, pile warp 30 is raisedhalf way in the low float position, binder warp 20 is raised half wayand all other warps are lowered. Wire 27 is inserted in the upper shedand a weft 25 is inserted in the lower shed.

In the sixth step, binder warp 21 is lowered, all other warps are raisedhalf way and a shot of Weft 26 is inserted in the lower shed.

In the seventh step, pile warp 24 is fully raised, pile warp 30 israised half way, binder warp 21 is raised half way and all other warpsare lowered. A wire 27 is inserted in the upper shed and a shot of weft25 is inserted in the lower shed.

In the eighth step, binder warp 26 is lowered and all other warps areraised half Way and a shot of weft 26 is taken in the lower shed.

Thus in the form of Figure 1 a long low float over three upper weftshots is provided under the wires whereever the jacquard requires. Dueto the length of this float it retains considerable resilience and whenthe wires are withdrawn to form cut pile 28, as shown in Figure 2, thelow float 30 springs up above the height of the pile, since the pile islimited to a height of 0.150 inch.

In case a heavy pile warp yarn is used, having a weight between 20 and45 yards per ounce, and preferably of three ply or more, a float overtwo upper wefts as shown in 30, Figure 1, will retain enough resilienceso that it will rise above the low cut pile as shown at 30 in Figure 2.

Thus it will be evident that, by one of these two expedients, either alow float over three upper wefts or longer or a low float over at leasttwo upper wefts and having a weight of 20 to 45 yards per ounce, aspring is retained in the low float so that although it is producedinitially under the wire, it will nevertheless rise above the low pilewhen wires are withdrawn and the pile is cut. Thus a close weave isobtained without the necessity of using non-cutting Wires, with thenovel effect described.

Especially when reliance is had on the use of a relatively heavy faceyarn, it is decidedly desirable to use a yarn having suitable loft. Thiswill be accomplished by employing a two ply or preferably a three ormore ply yarn having a twist in the ply of l to 2.5 turns per inch. Thetwist in the single is unimportant for the present purpose.

In view of my invention and disclosure, variations and modifications tomeet individual whim or particular need will doubtless become evident toothers skilled in the art, to obtain all or part of the benefits of myinvention without copying the method and fabric shown, and I, therefore,claim all such insofar as they fall within the reasonable spirit andscope of my claims.

Having thus described my invention, what I claim as new and desire tosecure by Letters Patent is:

1. The method of weaving a pile carpet, using a plurality of pile warpends, binder warp ends, stulfer warp' ends and wefts which compriseslowering pile warp ends into lower position, raising some other warpends, inserting a shot of weft above the pile warp ends; raising some ofthe pile warpends to upper wposition, raising some of the pile warp endsto intermediate position, lower- 0 the ends previously in the upperposition to the lower position, inserting a cutting wire in the, upperposition and inserting a shot of weft in thelower position; continuingthe weave and finally lowering the pile Warp ends previously in theintermediate position to the lower position, raising some other warpends half way and inserting a shot of weft above the pile warp endsformerly in the intermediate position to terminate a low float, the lowfloat extending over at least two wefts in the face of the fabric, thepile warp ends having a weight of between 20 and 45 yards per ounce andthe height of the cutting wires being'not in excess of 0.150 inch, andwithdrawing into intermediate position and lowering other warp ends,

inserting cutting wires beneath the. fully raised pile warp ends andabove the intermediate pile warp ends and insertingtwefts betweenthewarp ends in the intermediate and the lower positions, maintainingcertain pilewarp ends in floating positionbeneath the wires over atleast three wefts above the stuffer warp, the wire height not exceeding0.150 inch, and withdrawing the wires thereby cutting the pile warp endsover the wires and releasing the floats beneath the wires so that theyrise above 'the 7 level of the cut pile warp ends., j 7

4. A carpet having pile warp ends, binder warp ends, stufier warp endsand wefts interwoventogether, the pile warp ends rising in cut piletufts all of length not eXceeda ing 0.150 inch and uncut low floatsextending over at least two upper wefts and having a weight between 20 Vand yards per ounce, the floats rising in the face of the fabric abovethe cut pile tufts.

5. A carpet according to claim 4, in which the pile warp ends arernultipleand have a twist in the ply of from 1 to 2.5 turns per inch. 7

6. A carpet having pile warp ends, binder warp ends, stuffer warp endsand wefts interwoven together, the pile warp ends rising in cut piletufts all of length not exceeding 0.150 inch there being uncut lowfloats extending over at least three upper wefts and the floats risingabove the cut pile in the face of the fabric.

Harding July 26, 1949 Harding 'Aug. 25, 1953 a new

